Machining Tool Path Correction Using Measured Error Maps
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Solution Overview
Problem
Machining processes often result in parts that deviate from their nominal models due to real-world conditions and dynamic forces, leading to costly errors, especially in industries requiring precise specifications like aerospace and medical fields, where pre-programmed instructions for common features cannot be adjusted to correct errors such as a circle being cut as an ellipse.
Innovation Solution
A method and apparatus that measure deviations of machined parts from nominal models, calculate error maps, and adjust cutting instructions to correct these deviations, allowing for feature-based corrections to the machining process, thereby producing parts with reduced errors by editing specific coordinate sets of cutting instructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pre-programmed cutting instructions are used for common features, then machining efficiency is improved, but manufacturing precision deteriorates due to inability to correct errors like circles being cut as ellipses
Solution Approach 1:
The system modifies cutting instruction parameters dynamically by applying error map corrections to coordinate sets. The error map contains deviation data that adjusts original cutting parameters to compensate for machine tool inaccuracies, transforming fixed pre-programmed instructions into adaptable instructions that maintain both efficiency and precision
Solution Approach 2:
The system implements a feedback loop where measurement data from inspected parts is used to generate error maps, which then correct cutting instructions for subsequent parts. This closed-loop feedback mechanism allows the system to learn from previous machining errors and continuously improve precision while maintaining automated machining efficiency
2Manufacturing precision
If measurement and error correction processes are implemented, then manufacturing precision is improved, but device complexity and process time increase
Solution Approach 1:
The system integrates multiple functions into a unified platform that handles measurement data acquisition, error map generation, cutting instruction correction, and automated part production. By making the system multi-functional, it reduces the need for separate dedicated devices for each operation, thereby managing complexity while achieving high precision through iterative correction
3Manufacturing precision
If measurement and error correction processes are implemented, then manufacturing precision is improved, but production time increases
Solution Approach 1:
The system performs error correction in advance by generating error maps from initial part measurements and applying corrections to cutting instructions before producing subsequent parts. This preliminary correction action prevents errors from propagating through production, reducing rework time and accelerating the overall production cycle despite the initial measurement overhead
Data Source
AI summary
A method of manufacturing a plurality of parts receives cutting instructions to produce a part based on a nominal model of the part. After cutting a given part, the method measures at least one particular feature of the given part with a coordinate measuring machine and subsequently calculates an error of the given part by determining an initial deviation between the cutting instructions and the nominal model. The cutting instructions are then adjusted based on the error to obtain updated cutting instructions, where the updated cutting instructions have a reduced deviation from the initial deviation with regard to the nominal model. The method then uses the updated cutting instructions to produce another part having a reduced error deviation from the nominal model.